Assembly of worldwide AC adapter supporting foldable prongs

ABSTRACT

An AC (Alternating Current) plug for providing power via a power circuit is assembled by: selecting a cover that includes prongs and structures on an inner side; positioning a PCB (printed circuit board) that includes contact pads connecting the PCB to the power circuit on structures of the inner side of the cover; positioning the spring mounted terminals on structures on the inner side of the cover such that a first end of each spring mounted terminal is positioned on a contact pad of the PCB; positioning a cap on the spring mounted terminals, the PCB and the cover, such that assembly holes of the cap, the PCB and the cover are aligned; and fastening the cap to the cover, such that the first end of each spring mounted terminal is secured against a respective contact pad and each spring mounted terminal is loaded and exerts a force against a prong.

CROSS REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to, and is a continuation ofco-pending, commonly assigned U.S. patent application Ser. No.16/258,038, filed Jan. 25, 2019 and also entitled “Assembly of WorldwideAC Adapter Supporting Foldable Prongs,” which is hereby incorporatedherein by reference.

FIELD

This disclosure relates generally to Information Handling Systems(IHSs), and more specifically, to AC (Alternating Current) adapters forcharging portable IHSs.

BACKGROUND

As the value and use of information continues to increase, individualsand businesses seek additional ways to process and store information.One option is an Information Handling System (IHS). An IHS generallyprocesses, compiles, stores, and/or communicates information or data forbusiness, personal, or other purposes. Because technology andinformation handling needs and requirements may vary between differentapplications, IHSs may also vary regarding what information is handled,how the information is handled, how much information is processed,stored, or communicated, and how quickly and efficiently the informationmay be processed, stored, or communicated. The variations in IHSs allowfor IHSs to be general or configured for a specific user or specific usesuch as financial transaction processing, airline reservations,enterprise data storage, global communications, etc. In addition, IHSsmay include a variety of hardware and software components that may beconfigured to process, store, and communicate information and mayinclude one or more computer systems, data storage systems, andnetworking systems.

Certain IHSs, such as laptops, tablets and mobile phones, are portableand are designed to operate using power supplied by rechargeablebatteries. Power drawn from an electrical outlet may be used to chargethe batteries of a portable IHS. Since the batteries of IHSs typicallyoperate using DC (Direct Current) power, an AC adapter (i.e., AC/DCadapter or AC/CD converter) is required to convert the AC power from thewall outlet to DC power that can be used to charge the batteries. On oneend, AC adapters include an AC plug that is inserted into the outlet.Many different types of AC plugs are utilized throughout the world, withdifferent plugs from different regions utilizing different numbers,shapes and orientations of the prongs that conform to the electricaloutlets used in a region. On the other end, AC adapters include a DCplug that includes a connector that is received by a power port of theportable IHS, where the power port is typically on a side or an edge ofthe IHS enclosure.

SUMMARY

In various embodiments, a method is provided for assembling an AC(Alternating Current) plug for providing power via a power circuit. Themethod includes: selecting a top cover for the AC plug, wherein an innerside of the top cover includes structures for receiving a PCB (printedcircuit board) and for receiving a plurality of spring mountedterminals, and wherein the top cover comprises a plurality of prongs;positioning the PCB on structures of the inner side of the top cover,wherein the PCB comprises a plurality of contact pads connecting the PCBto the power circuit; positioning the plurality of spring mountedterminals on structures on the inner side of the top cover, wherein afirst end of each spring mounted terminal is positioned on a contact padof the PCB; positioning a cap on the spring mounted terminals, the PCBand the top cover, wherein assembly holes of the cap, the PCB and thetop cover are aligned; and fastening the cap to the top cover, whereinthe first end of each spring mounted terminal is secured against thecontact pad, and wherein each spring mounted terminal is loaded andexerts a force against a prong of the plurality of prongs.

In additional method embodiments, the fastening connects the prongs tothe power circuit via the contact pads and wherein no wires are includedin the connections between the plurality of prongs and the powercircuit. In additional method embodiments, a first selected top covercomprises a plurality of slots, and wherein the each of the plurality ofprongs are foldable prongs that may be rotated into a slot of the topcover. In additional method embodiments, a second selected top covercomprises the plurality of prongs fixed to the outer side of the topcover. In additional method embodiments, the second selected top coveris selected from top covers comprising prongs conforming to electricaloutlets used in different geographic regions. In additional methodembodiments, the spring mounted terminals are positioned based on analignment of the second end of each of the spring mounted terminals withan alignment structure of the top cover. In additional methodembodiments, each of the plurality of prongs comprises a cam thatcontacts the respective spring mounted terminal when the foldable prongsare rotated to an extended position. In additional method embodiments,the cam of each of the plurality of prongs does not contact therespective spring mounted terminal when the foldable prongs are rotatedto a folded position.

In various additional embodiments, an AC (Alternating Current) plugprovides power to an Information Handling System (IHS) via a powercircuit. The AC plug includes: a top cover, wherein an inner side of thetop cover includes structures for receiving a PCB (printed circuitboard) and for receiving a plurality of spring mounted terminals, andwherein the top cover comprises a plurality of prongs; the PCBpositioned on structures of the inner side of the top cover, wherein thePCB comprises a plurality of contact pads connecting the PCB to thepower circuit; the plurality of spring mounted terminals positioned onstructures on the inner side of the top cover, wherein a first end ofeach spring mounted terminal is positioned on a contact pad of the PCB;and a cap positioned on the spring mounted terminals, the PCB and topcover, wherein assembly holes of the cap, the PCB and the top cover arealigned, wherein the cap is fastened to the top cover, wherein, due tothe fastening, the first end of each spring mounted terminal is securedagainst the contact pad, and wherein, due to the fastening, each springmounted terminal is loaded and exerts a force against a prong of theplurality of prongs.

In additional AC plug embodiments, the fastening connects the prongs tothe power circuit via the contact pads and wherein no wires are includedin the connections between the plurality of prongs and the powercircuit. In additional AC plug embodiments, the top cover comprises aplurality of slots, and wherein the each of the plurality of prongs arefoldable prongs that may be rotated into a slot of the top cover. Inadditional AC plug embodiments, the top cover comprises the plurality ofprongs fixed to the outer side of the top cover. In additional AC plugembodiments, the top cover is selected from top covers comprising prongsconforming to electrical outlets used in different geographic regions.In additional AC plug embodiments, the spring mounted terminals arepositioned based on an alignment of the second end of each of the springmounted terminals with an alignment structure of the top cover. Inadditional AC plug embodiments, each of the plurality of prongscomprises a cam that contacts the respective spring mounted terminalwhen the foldable prongs are rotated to an extended position. Inadditional AC plug embodiments, the cam of each of the plurality ofprongs does not contact the respective spring mounted terminal when thefoldable prongs are rotated to a folded position.

In various additional embodiments, an AC (Alternating Current) adapterprovides power to an Information Handling System (IHS) via a powercircuit. The AC adapter includes an AC plug assembled by: selecting atop cover for the AC plug, wherein an inner side of the top coverincludes structures for receiving a PCB (printed circuit board) and forreceiving a plurality of spring mounted terminals, and wherein the topcover comprises a plurality of prongs; positioning the PCB on structuresof the inner side of the top cover, wherein the PCB comprises aplurality of contact pads connecting the PCB to the power circuit;positioning the plurality of spring mounted terminals on structures onthe inner side of the top cover, wherein a first end of each springmounted terminal is positioned on a contact pad of the PCB; positioninga cap on the spring mounted terminals, the PCB and top cover, whereinassembly holes of the cap, the PCB and the top cover are aligned; andfastening the cap to the top cover, wherein the first end of each springmounted terminal is secured against the contact pad, and wherein eachspring mounted terminal is loaded and exerts a force against a prong ofthe plurality of prongs.

In additional AC adapter embodiments, the fastening connects the prongsto the power circuit via the contact pads and wherein no wires areincluded in the connections between the plurality of prongs and thepower circuit. In additional AC adapter embodiments, a first selectedtop cover comprises a plurality of slots, and wherein the each of theplurality of prongs are foldable prongs that may be rotated into a slotof the top cover. In additional AC adapter embodiments, a secondselected top cover comprises the plurality of prongs fixed to the outerside of the top cover, and wherein the second selected top cover isselected from top covers comprising prongs conforming to electricaloutlets used in different geographic regions.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention(s) is/are illustrated by way of example and is/arenot limited by the accompanying figures, in which like referencesindicate similar elements. Elements in the figures are illustrated forsimplicity and clarity, and have not necessarily been drawn to scale.

FIG. 1 is a block diagram depicting certain components of an IHSconfigured for operation with an AC power adapter according to variousembodiments.

FIG. 2 is a diagram depicting certain components of a prior art chargingsystem that includes an AC adapter that is coupled to a laptop computer.

FIG. 3A is a diagram depicting certain components of an AC plug withfoldable prongs according to various embodiments.

FIG. 3B is a diagram depicting certain components of an AC plug withfixed prongs according to various embodiments.

FIG. 4 is a diagram illustrating the assembly of an AC plug withfoldable prongs according to various embodiments.

FIG. 5A is a cutaway diagram depicting certain components of an AC plugwith foldable prongs in an extended position, according to variousembodiments.

FIG. 5B is another cutaway diagram depicting another view of an AC plugwith foldable prongs in an extended position, according to variousembodiments.

FIG. 5C is a cutaway diagram depicting an AC plug with foldable prongsin a folded position, according to various embodiments.

FIG. 6 is a diagram illustrating the assembly of an AC plug with fixedprongs according to various embodiments.

FIG. 7 is a cutaway diagram depicting certain components of an AC plugwith fixed prongs, according to various embodiments.

DETAILED DESCRIPTION

For purposes of this disclosure, an IHS may include any instrumentalityor aggregate of instrumentalities operable to compute, calculate,determine, classify, process, transmit, receive, retrieve, originate,switch, store, display, communicate, manifest, detect, record,reproduce, handle, or utilize any form of information, intelligence, ordata for business, scientific, control, or other purposes. For example,an IHS may be a personal computer (e.g., desktop or laptop), tabletcomputer, mobile device (e.g., Personal Digital Assistant (PDA) or smartphone), server (e.g., blade server or rack server), a network storagedevice, or any other suitable device and may vary in size, shape,performance, functionality, and price. An IHS may include Random AccessMemory (RAM), one or more processing resources, such as a CentralProcessing Unit (CPU) or hardware or software control logic, Read-OnlyMemory (ROM), and/or other types of nonvolatile memory.

Additional components of an IHS may include one or more disk drives, oneor more network ports for communicating with external devices as well asvarious I/O devices, such as a keyboard, a mouse, touchscreen, and/or avideo display. An IHS may also include one or more buses operable totransmit communications between the various hardware components. Anexample of an IHS is described in more detail below. FIG. 1 shows anexample of an IHS configured to implement the systems and methodsdescribed herein according to certain embodiments. It should beappreciated that although certain IHS embodiments described herein maybe discussed in the context of a personal computing device, otherembodiments may be utilized.

As described, certain portable IHSs may utilize AC adapters for drawingpower from an electrical outlet and converting the power for use inrecharging internal batteries from which the portable IHSs operate.However, once the charge of the internal batteries is depleted, the ACadapter must once again be used to recharge the batteries. In light ofthe need to frequently recharge batteries, a portable IHS is frequentlytransported along with an AC adapter. The resulting portability of ACadapters used for charging portable IHSs requires that such AC adaptersbe easy as possible to transport in ongoing support of the portable IHS.As provided, AC plugs vary in different regions. AC plugs from certainregions may support foldable prongs, while the orientation andarrangement of prongs in other regions may be more difficult to supportreliable folding prongs. In addition, the lower cost of fixed prongswill continue to drive demand for fixed prong plugs. Accordingly, anassembly process for AC plugs is preferred that supports both assemblyof both foldable and fixed prong plugs, while using as many componentsin common as possible in the assembly of the two types of plugs.

FIG. 1 is a block diagram illustrating certain components of an IHS 100configured for operation with an AC power adapter according to variousembodiments. In various embodiments, IHS 100 may include a powermanagement unit 115 that includes logic that powers IHS 100 based onpower drawn from an AC power adapter. While a single IHS 100 isillustrated in FIG. 1, IHS 100 may be a component of an enterprisesystem that may include any number of additional IHSs that may also beconfigured in the same or similar manner to IHS 100.

IHS 100 includes one or more processors 101, such as a CentralProcessing Unit (CPU), that execute code retrieved from a system memory105. Although IHS 100 is illustrated with a single processor 101, otherembodiments may include two or more processors, that may each beconfigured identically, or to provide specialized processing functions.Processor 101 may include any processor capable of executing programinstructions, such as an Intel Pentium™ series processor or anygeneral-purpose or embedded processors implementing any of a variety ofInstruction Set Architectures (ISAs), such as the x86, POWERPC®, ARM®,SPARC®, or MIPS® ISAs, or any other suitable ISA.

In the embodiment of FIG. 1, the processor 101 includes an integratedmemory controller 118 that may be implemented directly within thecircuitry of the processor 101, or the memory controller 118 may be aseparate integrated circuit that is located on the same die as theprocessor 101. The memory controller 118 may be configured to manage thetransfer of data to and from the system memory 105 of the IHS 100 via ahigh-speed memory interface 104.

The system memory 105 that is coupled to processor 101 provides theprocessor 101 with a high-speed memory that may be used in the executionof computer program instructions by the processor 101. Accordingly,system memory 105 may include memory components, such as such as staticRAM (SRAM), dynamic RAM (DRAM), NAND Flash memory, suitable forsupporting high-speed memory operations by the processor 101. In certainembodiments, system memory 105 may combine both persistent, non-volatilememory and volatile memory. In certain embodiments, the system memory105 may be comprised of multiple removable memory modules.

IHS 100 utilizes a chipset 103 that may include one or more integratedcircuits that are connect to processor 101. In the embodiment of FIG. 1,processor 101 is depicted as a component of chipset 103. In otherembodiments, all of chipset 103, or portions of chipset 103 may beimplemented directly within the integrated circuitry of the processor101. Chipset 103 provides the processor(s) 101 with access to a varietyof resources accessible via bus 102. In IHS 100, bus 102 is illustratedas a single element. Various embodiments may utilize any number of busesto provide the illustrated pathways served by bus 102.

As illustrated, a variety of resources may be coupled to theprocessor(s) 101 of the IHS 100 through the chipset 103. For instance,chipset 103 may be coupled to a network interface 109 that may supportdifferent types of network connectivity. In certain embodiments, IHS 100may include one or more Network Interface Controllers (NIC), each ofwhich may implement the hardware required for communicating via aspecific networking technology, such as Wi-Fi, BLUETOOTH, Ethernet andmobile cellular networks (e.g., CDMA, TDMA, LTE). As illustrated,network interface 109 may support network connections by wired networkcontrollers 122 and wireless network controller 123. Each networkcontroller 122, 123 may be coupled via various buses to the chipset 103of IHS 100 in supporting different types of network connectivity, suchas the network connectivity utilized in applications of the operatingsystem of IHS 100.

Chipset 103 may also provide access to one or more display device(s)108, 113 via graphics processor 107. In certain embodiments, graphicsprocessor 107 may be comprised within a video or graphics card or withinan embedded controller installed within IHS 100. In certain embodiments,graphics processor 107 may be integrated within processor 101, such as acomponent of a system-on-chip. Graphics processor 107 may generatedisplay information and provide the generated information to one or moredisplay device(s) 108, 113 coupled to the IHS 100. The one or moredisplay devices 108, 113 coupled to IHS 100 may utilize LCD, LED, OLED,or other display technologies. Each display device 108, 113 may becapable of receiving touch inputs such as via a touch controller thatmay be an embedded component of the display device 108, 113 or graphicsprocessor 107, or may be a separate component of IHS 100 accessed viabus 102. As illustrated, IHS 100 may support an integrated displaydevice 108, such as a display integrated into a laptop, tablet, 2-in-1convertible device, or mobile device. IHS 100 may also support use ofone or more external displays 113, such as external monitors that may becoupled to IHS 100 via various types of couplings.

In certain embodiments, chipset 103 may utilize one or more I/Ocontrollers 110 that may each support hardware components such as userI/O devices 111 and sensors 112. For instance, I/O controller 110 mayprovide access to one or more user I/O devices 110 such as a keyboard,mouse, touchpad, touchscreen, microphone, speakers, camera and otherinput and output devices that may be coupled to IHS 100. Each of thesupported user I/O devices 111 may interface with the I/O controller 110through wired or wireless connections.

In certain embodiments, sensors 112 accessed via I/O controllers 110 mayprovide access to data describing environmental and operating conditionsof IHS 100. For instance, sensors 112 may include geo-location sensorscapable for providing a geographic location for IHS 100, such as a GPSsensor or other location sensors configured to determine the location ofIHS 100 based on triangulation and network information. Variousadditional sensors, such as optical, infrared and sonar sensors, thatmay provide support for xR (virtual, augmented, mixed reality) sessionshosted by the IHS 100.

Other components of IHS 100 may include one or more I/O ports 116 thesupport removeable couplings with various types of peripheral externaldevices. For instance, I/O 116 ports may include USB (Universal SerialBus) ports, by which a variety of external devices may be coupled to IHS100. I/O ports 116 may include various types of ports and couplings thatsupport connections with external devices and systems, either throughtemporary couplings via ports, such as USB ports, accessible to a uservia the enclosure of the IHS 100, or through more permanent couplingsvia expansion slots provided via the motherboard or via an expansioncard of IHS 100, such as PCIe slots.

Chipset 103 also provides processor 101 with access to one or morestorage devices 119. In various embodiments, storage device 119 may beintegral to the IHS 100, or may be external to the IHS 100. In certainembodiments, storage device 119 may be accessed via a storage controllerthat may be an integrated component of the storage device. Storagedevice 119 may be implemented using any memory technology allowing IHS100 to store and retrieve data. For instance, storage device 119 may bea magnetic hard disk storage drive or a solid-state storage drive. Incertain embodiments, storage device 119 may be a system of storagedevices, such as a cloud drive accessible via network interface 109.

As illustrated, IHS 100 also includes a BIOS (Basic Input/Output System)117 that may be stored in a non-volatile memory accessible by chipset103 via bus 102. Upon powering or restarting IHS 100, processor(s) 101may utilize BIOS 117 instructions to initialize and test hardwarecomponents coupled to the IHS 100. The BIOS 117 instructions may alsoload an operating system for use by the IHS 100. The BIOS 117 providesan abstraction layer that allows the operating system to interface withthe hardware components of the IHS 100. The Unified Extensible FirmwareInterface (UEFI) was designed as a successor to BIOS. As a result, manymodern IHSs utilize UEFI in addition to or instead of a BIOS. As usedherein, BIOS is intended to also encompass UEFI.

In the illustrated embodiment, IHS 100 also includes a power managementunit 115 that receives power inputs used for charging batteries 124 fromwhich the IHS 100 operates. IHS 100 may include one or more power ports125 to which an AC adapter may be coupled. As described, an AC adaptermay draw AC from an electrical outlet and convert the AC to a DC outputthat is provided to an IHS via a DC connector. The DC connector portionof an AC adapter may be inserted into a compatible power port 125 of anIHS 100, thus providing the power to the IHS. The DC power inputreceived at power port 125 may be utilized by a battery charger 124 forrecharging one or more internal batteries 124 of IHS 100.

In certain embodiments, power management unit 115 of IHS 100 may includea power port controller 114 that is operable for detecting the couplingof an AC adapter to power port 125. Upon detecting the coupling of an ACadapter, the power port controller 114 may interrogate the AC adapter inorder to determine characteristics of the AC adapter. In certainembodiments, the AC adapter may be configured to report PSID (powersupply identification) information that specifies attributes of the ACadapter, such as a manufacturer, rating and model number.

In certain embodiments, power port controller 114 may be a component ofa system-on-chip from which the power management unit 115 operates. Incertain embodiments, power port controller may an embedded controllerthat is a motherboard component of IHS 100, or a component of a powermanagement unit 115 daughter card of IHS 100. In various embodiments, anIHS 100 does not include each of the components shown in FIG. 1. Invarious embodiments, an IHS 100 may include various additionalcomponents in addition to those that are shown in FIG. 1. Furthermore,some components that are represented as separate components in FIG. 1may in certain embodiments instead be integrated with other components.For example, in certain embodiments, all or a portion of thefunctionality provided by the illustrated components may instead beprovided by components integrated into the one or more processor(s) 101as a systems-on-a-chip.

FIG. 2 is a diagram depicting components of an existing charging system,where the system includes an AC power adapter 210 coupled to laptopcomputer 205. In the illustrated system, AC power adapter 210 is used tocharge the internal batteries of laptop computer 205. An AC poweradapter 210 include several connected components that operate to draw ACpower from an electrical outlet 215 and convert the AC input power to aDC output for delivery to laptop 205. One end of the AC power adapter210 includes an AC plug 210 a that includes three prongs that may bereceived by a socket provided by an AC electrical outlet 215.

As illustrated, an AC electrical cord 210 b of AC adapter 210 connectsAC plug 210 a to converter 210 c. One function of converter 210 c is toconvert the AC received from power cord 210 b to DC that can be used topower IHSs compatible with the AC adapter 210. In certain instances,converter 210 c may be referred to as a power brick. The outputgenerated by converter 210 c may be DC within a voltage range thatsupports the power requirements of IHSs compatible for charging using ACadapter 210. The DC output generated by converter 210 c is provided tolaptop 205 via a DC power cord 210 d that supplies the DC output via aconnector that is received by a power port of the laptop.

As illustrated, DC cord 210 d also includes a DC plug 210 f that may bereceived by a power port of converter 210 c. Similar to DC plug 210 ecoupled to IHS 205, the DC plug 210 f on the opposite end of DC cord 210d may be removed from the power port of converter 210 c. DC plug 210 eand DC plug 210 f may be interchangeable for use in the power port ofeither converter 210 c or IHS 205. In this manner, DC cord 210 d may bereversible. In other charging system, DC cord 210 d may be fixed toconverter 210 c.

FIGS. 3A and 3B are diagrams illustrating two types of AC plugs 300 and335 that are assembled using certain components in common and using atechnique that eliminates the need for wires connecting the prongs 315and 330 to the power circuit supported by the AC plugs. The AC plug 300of FIG. 3A is a foldable prong plug in which the prongs 315 may befolded into slots 320 provided in the top cover 325 of the plug. The ACplug 335 of FIG. 3B is a fixed prong plug that is assembled using someof the common components and using the same technique for coupling fixedprongs 330 to the power circuit supported by the AC plug 335. Theassembly of AC plug 300 is described in detail with regard to FIG. 4 andthe assembly of AC plug 335 is described with regard to FIGS. 6 and 7.

FIG. 3A is a diagram depicting certain components of an AC plug 300 withfoldable prongs 315 according to various embodiments. In certainembodiments, AC plug 300 may be a component of an AC adapter used forcharging the internal batteries of an IHS in a manner similar to the useof AC adapter 210 in charging the batteries of laptop 205. In such ACadapter embodiments, AC plug 300 replaces the prior art, fixed-prong ACplug 210 a. Similar to the prior art fixed-prong AC plug 210 a of FIG.2, the prongs 315 of AC plug 300 may be received by a socket of an ACelectrical outlet. The AC power drawn from an outlet by prongs 315 maybe supplied to an AC adapter via wires of an AC cord 310. In certainembodiments, the wires of an AC cord 310 may connect the AC plug 300 toan AC/DC converter, such as converter 210 c of FIG. 2.

As described in additional detail with regard to FIGS. 5A-C, the prongs315 of AC plug 300 may be folded within slots 320 provided in the topcover 325 of the AC plug 300. In FIG. 3A, prongs 315 are illustrated inan extended position, thus allowing the prongs 315 of AC plug 300 to beinserted into the socket of an AC outlet. When not plugged into an ACoutlet, the prongs 315 may be folded into slots 320 such that the prongs315 are recessed within the housing of the AC plug 300 formed by the tub305 and top cover 325. While retracted in this manner, the portabilityof the AC adapter utilizing AC plug 300 is improved as the retractedprongs no longer protrude from the housing, thus preventing the prongs315 from damaging other items and reducing the bulkiness of the ACadapter.

FIG. 3B is a diagram depicting certain components of an AC plug 355 withfixed prongs 330 incorporated into a top cover 360, according to variousembodiments. As with AC plug 300 of FIG. 3A, AC plug 305 may be acomponent of an AC adapter used for charging the internal batteries ofan IHS and thus replaces the existing, fixed-prong AC plug 210 a of FIG.2. The AC power drawn from an outlet by prongs 355 may be supplied to anAC adapter via wires of an AC cord 310. In certain embodiments, thewires of an AC cord 310 may connect the AC plug 355 to an AC/DCconverter, such as converter 210 c of FIG. 2.

The fixed prongs 330 of AC plug 355 may be received by a socket of an ACelectrical outlet. As described, many different types of AC plugs areutilized throughout the world, with different plugs from differentregions utilizing different numbers, shapes and orientations of theprongs that conform to the electrical outlets used in a region. In NorthAmerica, most general-purpose electrical outlets deliver 120 V of AC ata frequency of 60 hertz using a two-prong (Type A) or a grounded,three-prong (Type B) plug. Through the selection of top cover 360, theAC plug 355 of FIG. 3B, has been assembled as a Type G plug, withrectangular prongs arranged in a triangular pattern, such as utilized inthe United Kingdom. Other common AC plugs that may be selected throughthe selection of a top cover include Type C plugs, used in Europe, thatutilize two rounded prongs and the Type I plugs, used in Australia, thatutilize flat prongs arranged in a V-configuration with an optionalgrounding prong.

As described in additional detail with regard to FIGS. 6 and 7, thefixed prong AC plug 355 may be constructed using the same assemblytechnique as used to assemble the foldable prong AC plug 300. Using thisassembly technique, the prongs 315 and 330 are secured in a manner thatdoes not require any wires to connect the prongs to the power circuit.Both types of AC plugs 300 and 355 utilize a common tub 305 that issealed by installing a top cover supporting foldable prongs 325 or a topcover supporting a particular type of fixed prong outlet, such as theType G plug 360. By fastening different types of top covers 325, 360 tothe common tub 305, different types of AC plugs with different prongconfigurations may be assembled using a common technique and certaincommon parts, others of which are described with regard to the belowembodiments.

In certain embodiments, AC plugs 300 and 335 may be components of an ACadapter used to provide power to an IHS such as the laptop 205 of FIG.2. In other embodiments, AC plugs 300 and 335 may be components of an ACadapter similarly used to charge the batteries of other types ofportable IHSs, such as tablets, 2-1 convertible laptops, mobile phonesand smart watches. Embodiments may be implemented using all varieties ofIHSs that operate on DC power supplied by internal rechargeablebatteries and that also utilize an AC converter that may be plugged intoan electrical outlet and used to charge the batteries of an IHS.

In certain embodiments, AC plugs 300 and 335 may be constructed usingdifferent configurations of top covers 325 and 360 and tubs 305. Forinstance, in certain embodiments, top cover 325 may be shaped more likea tub with an outer bottom side from which the prongs protrude and withwalls that form the sides of the AC plug. The inner portions of such tubshaped top covers may support assembly in the same manner as described.In such embodiments, a blank cover may be used to seal the tub-shapedtop cover. Various other configurations of covers and bases may beutilized to form AC plugs according to embodiments.

FIG. 4 is a diagram illustrating the assembly of an AC plug 400 withfoldable prongs according to various embodiments. In certainembodiments, the AC plug 400 with foldable prongs may be assembledthrough stacking and fastening of the depicted components in theillustrated order. The foldable prong AC plug 400 may be constructedusing the AC plug top cover 405 as an assembly base to which theremaining items of AC plug 400 may be fastened. In the illustratedembodiment, top cover 405 is the portion of AC plug 400 from whichprongs 425 protrude while in an extended position. As provided ingreater detail in FIGS. 5A-C, the inner side of top cover 405 includesstructures 420 that provide slots in which prongs 425 are recessed whilein a retracted position.

The assembly of a foldable prong AC plug 400 may begin with theselection of a top cover 405 that supports foldable prongs, inparticular by including slots in which the prongs may be recessed andstructures in which the foldable prongs may be mounted, but may stillrotate between extended and recessed positions. In various embodiments,prongs 425 may be connected to each other via an insulating, cylindricalrod 425 a. A preliminary step in assembling a foldable prong AC plug 400may be securing prongs 425 in the top cover 405. In particular, prongs425 may inserted and secured within a structure on the inner side of topcover 405 that includes a saddle 405 a that receives the insulatingcylinder 425 a that connects the prongs 425. While resting on saddle 405a, cylinder 425 a may be rotated, thus allowing prongs 425 to be foldedwithin the slot structures 420 provided by top cover 405. In certainembodiments, prongs 425 may include protrusions 425 b that may besnapped into corresponding holes 405 b provided by the structures on theinners side of top cover 405, thus securing prongs 425 within the topcover, while still allowing rotation of the prongs 425 about thecylinder 425 a such that the prongs 425 protrude from the outer side oftop cover 405.

Upon selection of a top cover 405 that includes installed foldableprongs 425, a PCB (printed circuit board) 410 may be positioned on theinner side of the top cover 405 of the AC plug such that assembly holesof the PCB 410 and top cover 405 are aligned. As illustrated, PCB 410may include electrical contact pads 415 that are positioned on the PCB410 such that one end of each of the spring mounted terminals 430 arepositioned on one of the contact pads 415. Electricity drawn from prongs425, when in an extended position and inserted in an AC outlet, istransmitted to the contact pads 415 via the spring mounted terminals430, as described in detail in FIG. 5A. In certain embodiments, PCB 410may include circuitry that transmits electricity received at contactpads 415 to the wires of an AC cord connected to the AC plug 400, suchas AC cord 310 of FIG. 3.

Once the PCB 410 have been positioned on the top cover 405, springmounted terminals 430 may be stacked on to the assembly. In certainembodiments, spring mounted terminals 430 may be metal spring clips thatare unloaded when prongs 425 are in a retracted position and are loadedby the rotation of prongs 425 to an extended position. In certainembodiments, each spring mounted terminal 430 may be positioned duringassembly by aligning a hole 445 on one end of the terminal with a pegprovided on a surface of the structure forming a slot 420 provided bythe top cover 405. Other embodiments may utilize other alignmentfeatures for positioning the spring mounted terminals 430.

Aligned in this manner, each spring mounted terminal 430 may be securedin place on one end by the peg, while the other end of the springmounted terminal 430 is positioned on one of the contact pads 415 of thePCB. As described in additional detail with regard to FIG. 5A, a cap 435may be fastened to the housing 405 using screws 440 such that thestacked components are fixed together, while still allowing rotation ofthe prongs 425 about the saddle 405 a portion of top cover 405.Assembled in this manner, this portion of the AC plug 400 does notutilize any wires, thus simplifying the assembly process and improvingreliability of the AC plug 400. By eliminating wires between prongs 425and the power circuit, no wire harnesses or soldering is required toconnect the prongs to the power circuit accessed via PCB 410. Instead,prongs 425 are connected to the contact pads 415 of PCB 410 through thefastening of cap 435. By eliminating wire harness connection from theprongs 425 to PCB 410, the cost of PCB 410 is reduced, in addition tomaintaining the simplicity of the described assembly process of AC plug400.

FIG. 5A is a cutaway diagram depicting certain components of anassembled AC plug, according to various embodiments, with foldableprongs that are in an extended position. As described, the components ofan AC plug according to embodiments may be stacked and secured togetherby fastening a cap 530 to a top cover 520 of the AC plug. By fasteningcap 530 in this manner, PCB 525 is also fastened to the top cover 520.FIG. 5B is cutaway diagram depicting a rotated perspective of the ACplug of FIG. 5A. As illustrated in FIG. 5B, with the assembly holes ofthe cap 530, PCB 525 and top cover 520 aligned, screws 550 may be usedto fasten the cap 530 to the top cover 520 such that the spring mountedterminal is secured against the top cover 520 and the contact pad 560 ofPCB 525, which is also secured to the top cover 520.

As described, during assembly, each spring mounted terminal 535 may bepositioned on top cover 520 by aligning locating slots on one of thespring mounted terminal 535 with peg structures 555 located on astructure provided on the inner side of top cover 520, where each suchstructure includes a cavity that is a slot 515 in which a prong may berecessed. Positioned in this manner, the other end of the spring mountedterminal 535 is positioned on the contact pad 560 of PCB 525. Byfastening cap 530, the spring mounted terminal 535 is secured in placeabove prong 550 with one end of the terminal secured to a contact pad560.

In FIG. 5A, prong 505 is in an extended position and is thus ready forinsertion into a receptacle of an AC outlet. In this position, a cam 540protruding from prong 505 is in contact with the spring mounted terminal535. Once the AC plug is plugged into an outlet, electricity flows tothe power cord via the pathway established by the cam 540 of prong 505in contact with the spring mounted terminal 535, which is securedagainst a contact pad 560 of PCB 525. As described, PCB 525 includescircuitry for routing power from the contact pads 560 to an AC cordconnected to the top cover 520. Using this configuration, power may beprovided to an IHS via an AC adapter.

As provided above, many IHSs are portable DC devices that rely on an ACadapter in order to provide power for charging the internal batteries ofthe portable devices. In many instances, a portable device istransported along with an AC adapter for use in occasional or regularrecharging of the portable IHS batteries. Accordingly, an AC adapterutilized by a portable IHS is preferably also portable. Upon terminatinga charging session, an AC plug is unplugged from an AC outlet. In theembodiments of FIGS. 5A and 5B, once unplugged, prong 505 may be rotatedin direction 510 until the prong 505 is recessed within the slot 515provided by top cover 520. As described, prong 505 may be connected toanother prong of the AC plug via a connecting cylinder that can berotated within a saddle structure of top cover 520, thus allowing theprongs 505 to be rotated in direction 510. In FIG. 5B, the inside cavityof slot 515 is exposed by the cutaway illustrations that removes aportion of the top cover 520 structure that forms the slot. This cutawayof FIG. 5B also removes certain portions of top cover 520 structuresthat secure the prong 505 within the top cover 520.

FIG. 5C is a cutaway diagram depicting an AC plug with foldable prongsin a folded position, according to various embodiments. With the prong505 rotated to completion in direction 510, prong 505 now rests withinslot 515 of the top cover 520, such that prong 505 is recessed withinthe slot 550. And this folded position, the cam 540 of prong 505 hasbeen rotated away from spring mounted terminal 535. The rotation ofprong 505 to a recessed position results in a flat portion 545 of prong505 being positioned below the spring mounted terminal 535 such that thespring extends to an unloaded configuration. As illustrated, unlike cam540, the flat portion 545 of prong 505 does not protrude towards thespring mounted terminal. Accordingly, the power circuit has been openedand power can no longer flow between prong 505 and the spring mountedterminal 535.

As described, prong 505 may be rotated to an extended position, such asin FIG. 5A, in which the prong 505 is connected to the power circuit viacontact with the spring mounted terminal 535 by the cam 540 portion ofthe prong. In the extended position, cam 540 loads the spring mountedterminal 535 such that it exerts force against cam 540 and maintains thespring mounted terminal 535 securely in contact with cam 540. The forceexerted by spring mounted terminal 535 also serves as a detent thatprevents the prongs from rotating freely. From this loaded position,prong 505 may then be rotated to a retracted, unloaded position, such asin FIG. 5C, in which the prong 505 is no longer connected to the powercircuit. Importantly, embodiments that support a foldable prong 505 inthe described manner are connected to the power circuit without anywires connecting the prong 505 to the power circuit. In particular, nosoldering or wire harnesses are required to connect the prong 505 to thepower circuit provided by PCB 525. By eliminating the use of such wires,the simplicity and economy of the assembly process described in withregard to FIG. 4 is maintained. The components comprising the foldableprong of an AC plug may be stacked as described and fastened togetherusing only the screws that secure the cap 530 to the top cover 520,while also securing the spring mounted terminal 535 and PCB 525 inplace. Without wires connecting the prong 505 to the power circuit, thestacked assembly process of FIG. 4 may be completed without soldering,thus improving reliability in addition to simplifying the assembly ofthe AC plug.

This assembly process of FIG. 4 described with regard to a foldableprong AC plug 400 may also be utilized according to various embodimentsto assemble a fixed prong AC plug, such as described with respect toFIG. 3B. FIG. 6 is a diagram illustrating the assembly, according tovarious embodiments, of an AC plug 600 with fixed prongs. The AC plug600 with fixed prongs may be assembled through stacking and fastening ofthe depicted components in the illustrated sequence. As with theassembly of the foldable prong AC plug, the fixed prong AC plug 600 maybe constructed by using the AC plug top cover 605 as a platform on whichthe remaining components of the plug are assembled. As illustrated, topcover 605 is the portion of the AC plug from which prongs 625 protrude.

During assembly of AC plug 600, the top cover 605 may be utilized as abase to which the described components are fastened. As illustrated,each of the prongs 625 may protrude to the inner side of the top cover605 thus providing a connection surface on the inner side of the topcover 605. Various additional techniques may be utilized for providingconnection surfaces to the plugs on the inner side of top cover 605. Theassembly process may continue for fixed prong applications, with thepositioning of spring mounted terminals 630 on the inner surface of topcover 605. As illustrated, one end of each spring mounted terminal 630may be positioned such that a portion of each spring mounted terminal630 rests on the connection surface of one of the prongs 625.

As described in additional detail with regard to FIG. 7, each springmounted terminal 630 may include a locating hole that fits around a pegor other structure provided on the inner side of top cover 605. Once aspring mounted terminal 630 has been positioned using the peg, certainembodiments may utilize a bushing 645 that also fits on the portion ofthe peg that protrudes through the locating hole of the spring mountedterminal. Such bushings 645 may serve to secure the spring mountedterminal 630 in position and may also serve as buffer used to protectthe PCB which will be next layer added to the assembly.

With the spring mounted terminals 630 in place, the assembly process maycontinue with the positioning of the PCB (printed circuit board) 610 onthe top cover 605 of the AC plug such that assembly holes of the PCB 610and top cover 605 are aligned. Additional features for positioning PCB610 may be provided by the top cover 605. As illustrated in FIG. 7, incertain embodiments, PCB 610 may be positioned such that it is beneathone end of the spring mounted terminal 630, once the assembly has beencompleted. Accordingly, in some embodiments, the positioning of PCB 610may include sliding the PCB 610 underneath the suspended ends of thespring mounted terminals 635. The positioning of the PCB 610 in thismanner may also include positioning each suspended end of a springmounted terminal 635 above a contact pad 615 provided on the PCB 610.

Once the PCB 610 has been positioned in this manner, as with thefoldable prong AC plug, assembly of AC fixed prong AC plug 600 may becompleted by fastening a cap 635 to the top cover 605 using screws 640such that the stacked components are fixed together. In certainembodiments, the same cap 635 may be utilized in the assembly of bothfixed prong and foldable prong embodiments. In fastening cap 635 tocomplete the assembly, the spring mounted terminals 630 are secured suchthat they are in contact with the contact pads 615 of PCB 610 on oneend, while also securely in contact with a connection surface for one ofthe prongs 625.

Electricity drawn from prongs 625 may be transmitted to the contact pads615 via the spring mounted terminals 630, in the same manner as thespring mounted terminal in the foldable prong plug of FIGS. 4 and 5A-C.As with the foldable prong plug, PCB 610 of fixed prong AC plug 600 mayinclude circuitry that transmits electricity received at contact pads615 to the wires of an AC cord connected to the AC plug 600, such as ACcord 310 of FIG. 3B. In certain embodiments, the same PCB 610 may beutilized for both fixed prong and foldable prong AC plugs according toembodiments.

FIG. 7 is a cutaway diagram depicting certain components of an AC plug700 with fixed prongs, such as a portion of plug 600 assembled accordingto FIG. 6. As described with regard to the assembly, each spring mountedterminal 730 may be positioned during by aligning a hole on one end ofthe terminal with a peg 750 provided on the top cover 705. Otherembodiments may utilize other alignment features for positioning thespring mounted terminals 630. Aligned in this manner, each springmounted terminal 730 may be secured in place on one end by the peg 750,while the other end of the spring mounted terminal 730 is securedagainst one of the contact pads of the PCB 710.

In certain embodiments, spring mounted terminals 730 may be metal springclips that are in an unloaded state prior to assembly. During assembly,spring mounted terminals 730 may be loaded such that they exert amoderate force against the connection surface of a prong 725 thatprotrudes through the top cover 705 and such that the spring mountedterminals 730 also exert enough force against top cover 635 to remainsecured by the top cover 635 against a connection pad of the PCB 710.The top cover 605, 705 in the illustrative embodiment of FIGS. 6 and 7is a Type G plug. Different regionalized top covers will presentdifferent configurations of prongs. Accordingly, different geometries ofspring mounted terminals may be utilized in different embodiments in thesame manner as the illustrative spring mounted terminals describedherein.

As with the foldable prong plug of FIGS. 4 and 5A-C, the assembly of thefixed prong AC plug 600 and 700 in this manner, the fixed prongs of ACplug 700 are coupled to the power circuit without utilizing any wires inthis coupling, and thus without requiring any soldering or wiringharnesses to connect the prongs to the PCB that provides connections tothe power circuit. As described, eliminating such wiring reduces cost,improves manufacturing efficiency and improves reliability. Thedescribed assembly process also allows the use of several commoncomponents for both fixed prong and foldable prong, including the tub305 and AC power cord 310 of FIGS. 3A and 3B, as well as a common PCB410, 610, that connects the spring mounted terminals to the powercircuit and a common cap 435, 635 that is used to fasten and secure thecomponents of the AC plugs 400 and 600 in place.

It should be understood that various operations described herein may beimplemented in software executed by processing circuitry, hardware, or acombination thereof. The order in which each operation of a given methodis performed may be changed, and various operations may be added,reordered, combined, omitted, modified, etc. It is intended that theinvention(s) described herein embrace all such modifications and changesand, accordingly, the above description should be regarded in anillustrative rather than a restrictive sense.

The terms “tangible” and “non-transitory,” as used herein, are intendedto describe a computer-readable storage medium (or “memory”) excludingpropagating electromagnetic signals but are not intended to otherwiselimit the type of physical computer-readable storage device that isencompassed by the phrase computer-readable medium or memory. Forinstance, the terms “non-transitory computer readable medium” or“tangible memory” are intended to encompass types of storage devicesthat do not necessarily store information permanently, including, forexample, RAM. Program instructions and data stored on a tangiblecomputer-accessible storage medium in non-transitory form may afterwardsbe transmitted by transmission media or signals such as electrical,electromagnetic, or digital signals, which may be conveyed via acommunication medium such as a network and/or a wireless link.

Although the invention(s) is/are described herein with reference tospecific embodiments, various modifications and changes can be madewithout departing from the scope of the present invention(s), as setforth in the claims below. Accordingly, the specification and figuresare to be regarded in an illustrative rather than a restrictive sense,and all such modifications are intended to be included within the scopeof the present invention(s). Any benefits, advantages, or solutions toproblems that are described herein with regard to specific embodimentsare not intended to be construed as a critical, required, or essentialfeature or element of any or all the claims.

Unless stated otherwise, terms such as “first” and “second” are used toarbitrarily distinguish between the elements such terms describe. Thus,these terms are not necessarily intended to indicate temporal or otherprioritization of such elements. The terms “coupled” or “operablycoupled” are defined as connected, although not necessarily directly,and not necessarily mechanically. The terms “a” and “an” are defined asone or more unless stated otherwise. The terms “comprise” (and any formof comprise, such as “comprises” and “comprising”), “have” (and any formof have, such as “has” and “having”), “include” (and any form ofinclude, such as “includes” and “including”) and “contain” (and any formof contain, such as “contains” and “containing”) are open-ended linkingverbs. As a result, a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more elements possesses those oneor more elements but is not limited to possessing only those one or moreelements. Similarly, a method or process that “comprises,” “has,”“includes” or “contains” one or more operations possesses those one ormore operations but is not limited to possessing only those one or moreoperations.

The invention claimed is:
 1. A method of assembling an AC (AlternatingCurrent) plug for providing power, the method comprising: selecting atop cover for the AC plug, wherein an inner side of the top coverreceives a PCB (printed circuit board) and a plurality of spring mountedterminals, and wherein the top cover comprises a plurality of prongs;positioning the PCB on the inner side of the top cover, wherein the PCBcomprises a plurality of contact pads; positioning the plurality ofspring mounted terminals on the inner side of the top cover, wherein afirst end of each spring mounted terminal is positioned on a contact padof the PCB; positioning a cap on the spring mounted terminals, the PCBand the top cover; and fastening the cap to the top cover, wherein thefastening secures the first end of each spring mounted terminal againstthe contact pad, and wherein the fastening positions each spring mountedterminal for contact with a prong of the plurality of prongs.
 2. Themethod of claim 1, wherein the spring mounted terminals are positionedbased on an alignment of the second end of each of the spring mountedterminals with an alignment structure of the top cover.
 3. The method ofclaim 1, wherein the fastening connects the prongs to a power circuitvia the contact pads.
 4. The method of claim 3, wherein no wires areincluded in the connections between the plurality of prongs and thepower circuit.
 5. The method of claim 1, wherein a second selected topcover comprises the plurality of prongs fixed to the outer side of thetop cover.
 6. The method of claim 5, wherein the second selected topcover is selected from top covers comprising prongs conforming toelectrical outlets used in different geographic regions.
 7. The methodof claim 1, wherein a first selected top cover comprises a plurality ofslots, and wherein the each of the plurality of prongs are foldableprongs that may be rotated into a slot of the top cover.
 8. The methodof claim 7, wherein each of the plurality of prongs comprises a cam thatcontacts the respective spring mounted terminal when the foldable prongsare rotated to an extended position.
 9. The method of claim 8, whereinthe cam of each of the plurality of prongs does not contact therespective spring mounted terminal when the foldable prongs are rotatedto a folded position.
 10. An AC (Alternating Current) plug for providingpower to an Information Handling System (IHS) via a power circuit, theAC plug comprising: a top cover, wherein an inner side of the top coverreceives a PCB (printed circuit board) and a plurality of spring mountedterminals, and wherein the top cover comprises a plurality of prongs;the PCB positioned on the inner side of the top cover, wherein the PCBcomprises a plurality of contact pads; the plurality of spring mountedterminals positioned on structures on the inner side of the top cover,wherein a first end of each spring mounted terminal is positioned on acontact pad of the PCB; and a cap positioned on the spring mountedterminals, the PCB and top cover, wherein the cap is fastened to the topcover, and wherein the fastening secures the first end of each springmounted terminal against the contact pad, and wherein the fasteningpositions each spring mounted terminal for contact with a prong of theplurality of prongs.
 11. The AC plug of claim 10, wherein the top covercomprises the plurality of prongs fixed to the outer side of the topcover.
 12. The AC plug of claim 10, wherein the top cover is selectedfrom top covers comprising prongs conforming to electrical outlets usedin different geographic regions.
 13. The AC plug of claim 10, whereinthe fastening connects the prongs to a power circuit via the contactpads.
 14. The AC plug of claim 13, wherein no wires are included in theconnections between the plurality of prongs and the power circuit. 15.The AC plug of claim 10, wherein the top cover comprises a plurality ofslots, and wherein the each of the plurality of prongs are foldableprongs that may be rotated into a slot of the top cover.
 16. The AC plugof claim 15, wherein each of the plurality of prongs comprises a camthat contacts the respective spring mounted terminal when the foldableprongs are rotated to an extended position.
 17. The AC plug of claim 16,wherein the cam of each of the plurality of prongs does not contact therespective spring mounted terminal when the foldable prongs are rotatedto a folded position.
 18. An AC (Alternating Current) adapter forproviding power to an Information Handling System (IHS) via a powercircuit, wherein the AC adapter comprises an AC plug assembled by:selecting a top cover for the AC plug, wherein an inner side of the topcover receives a PCB (printed circuit board) and receives a plurality ofspring mounted terminals, and wherein the top cover comprises aplurality of prongs; positioning the PCB on structures of the inner sideof the top cover, wherein the PCB comprises a plurality of contact pads;positioning the plurality of spring mounted terminals on the inner sideof the top cover, wherein a first end of each spring mounted terminal ispositioned on a contact pad of the PCB; positioning a cap on the springmounted terminals, the PCB and top cover; and fastening the cap to thetop cover, wherein the first end of each spring mounted terminal issecured against the contact pad, and wherein the fastening positionseach spring mounted terminal for contact with a prong of the pluralityof prongs.
 19. The AC adapter of claim 18, wherein the fasteningconnects the prongs to a power circuit via the contact pads.
 20. The ACadapter of claim 18, and wherein no wires are included in theconnections between the plurality of prongs and the power circuit.